Wall mounted connecting block

ABSTRACT

An easily assembled connecting block provides interconnection between modular plugs and insulated telephone wires or the like. The connecting block includes: (i) a metallic lead frame comprising a number of flat elongated conductive elements that terminate in closely spaced flat wires at one end thereof, each conductive element terminating in two pairs of insulation-displacing contact fingers at the other end; and (ii) a dielectric block for receiving the closely spaced wires within a jack housing contained therein and for supporting the metallic lead frame. In one embodiment the connectors are an integral part of the lead frame itself and are &#34;sandwiched&#34; between a pair of dielectric blocks, each block having a plurality of corresponding slots for guiding wires into the region between opposing contact fingers of the connectors.

This is a division of application Ser. No. 204,811 filed June 10, 1988,now U.S. Pat. No. 4,820,192.

TECHNICAL FIELD

This invention relates to a telephone connecting block forinterconnecting modular plugs to a wire-pair, and more particularly toan efficient assembly of common components comprising the connectingblock.

BACKGROUND OF THE INVENTION

Connecting blocks are used extensively in telecommunications equipmentto provide telephones, modems and the like with easy access tocommunication cables and signal routing equipment. Easy access isachieved through the use of modular jacks and plugs which quicklyprovide connections for up to eight wires. Indeed, the popularity ofsuch modular equipment is such that it is standard equipment on newtelephones and data communications equipment. A desirable feature forconnecting blocks is the easy interconnection of insulated wires and theprovision of a junction point for the parallel connection of incomingwires, outgoing wires, and modular jack wires.

Known connecting blocks such as AT&T's 42-type connecting block, shownin U.S. Pat. No. 4,188,505, provide a hard-wire connection between themodular jack and the junction point. Here, the junction point comprisesa screwdown terminal for making electrical connection to a telephonecore whose wires have been stripped of their insulation. The associatedmodular jack is joined to the screw-down terminals through snap onscrew-engaging connectors.

U.S. Pat. No. 4,597,623 discloses a connector assembly that combines ascrew terminal with an insulation displacement connector for use in theconnecting block. Interconnection with modular jack wires may beaccomplished through screw-engaging connectors or spade connectorsindividually wired to the modular jack. Such hard-wire connections arenot easily adapted to automated assembly, are more costly, and detractfrom product uniformity.

U.S. Pat. No. 4,580,864 discloses a modular connecting block thatprovides hard-wire to hard-wire interconnections. Each junction pointoffers a wire-wrap capability and two insulation displacementconnections. However, no provision is offered for interconnection withmodular plugs.

It is, therefore, an object of the present invention to design aconnecting block having a modular jack and providing a junction pointfor easily interconnecting two or more insulated wires with each jackwire.

It is another object of the invention to provide a design that is suitedfor automated assembly.

SUMMARY OF THE INVENTION

In accordance with the present invention, a new design for a connectingblock is disclosed. The connecting block includes a metallic lead framecomprising a number of flat elongated conductive elements, eachterminated at one end in two or more pairs of opposing contact fingersthat reside in the same plane as the flat conductive elements. Theconductive elements are terminated at the other end in closely-spacedflat wires. The lead frame is held between a pair of generally flatdielectric blocks which cooperate in providing support for the leadframe.

In accordance with a further aspect oof the invention each of thedielectric blocks includes a plurality of corresponding slots along anedge thereof. When the lead frame is positioned between the dielectricblocks, the slots in the first dielectric block cooperate withcorresponding slots in the second dielectric block in guide wires,pressed therein, into electrical contact with the contact fingers.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 discloses a surface mount connecting block in accordance with thepresent invention;

FIG. 2 illustrates the interconnection and cooperation between adielectric block, a lead frame, and a jack frame in accordance with theinvention;

FIG. 3 discloses a flush mount connecting block showing a secondembodiment of the present invention;

FIG. 4 discloses a wall mount connecting block, showing a thirdembodiment of the present invention; and

FIG. 5 discloses a prior art connecting block.

DETAILED DESCRIPTION

The present invention offers a number of advantages includingcommonality of parts; automated assembly; robust construction; reliable,fast and familiar insulation-displacing connectors; and product lineconsistency. These advantages are inherent in each of three alternativeembodiments shown in FIGS. 1, 3, 4. First, however, a prior artconnecting block shown in FIG. 5, is considered.

FIG. 5 discloses a prior art connecting block similar to the WallTelephone Adapter Assembly shown in U.S. Pat. No. 4,369,340. Connectingblock 500 comprises steel base 501 which provides structural support formodular jack 530 and connector assemblies 520. Insulated wires 531 areattached to jack 530 in a prior assembly step. Further, these wires arespecially connected, at one end, to phosphor-bronze wires suitablyflexible for use within jack 530. At the other end, these wires arepushed into slots associated with connector assembly 520. Within each ofthe two connector assemblies shown, there are a pair of H-shapedconnectors, each leg of which comprises an opposing pair of contactfingers used for insulation displacement. The top portion of connectorassembly 520 is used for connecting four or six wires from modular jack530 while the bottom portion provides eight or twelve slotsrespectively, each having a pair of insulation displacing contactfingers, for interconnecting external wires (telephone cord) to jackwires 531. Wire insertion caps 510 are useful in pushing the externalwires into the slots. It is noted that although the connecting block ofFIG. 5 is an excellent design, it is not clearly adapted to automatedassembly.

SURFACE MOUNT CONNECTING BLOCK

FIG. 1 discloses a first embodiment of the invention in the form of asurface mount connecting block that may be attached to a surface usingeither mounting screws, double-sided tape or magnets. The connectingblock includes a number of components that may be readily assembled bymeans of automated equipment. Cover 100 and Base 160 are moldeddielectric materials that join together to contain and isolateelectrical connections within a convenient structure. Included withinbase 160 is an opening 161 for admitting a mounting screw that allowsfor easy surface mounting.

Dielectric block 120 is also molded from dielectric material andincludes apertures 126, 127 (see FIG. 2) for receiving up to eightinsulation-displacement connectors 140. After connectors 140 areinserted into dielectric block 120, lead frame 150 is pressed intoplace. Narrow portions 151 of the lead frame dielectrically engage eachof the downwardly extending contact fingers 144 of connectors 140.Metallic connectors 140 each include two pairs of upwardly extendingcontact fingers (141, 142) that displace the insulation of wiresinserted therein, make electrical connection, and mechanically hold thewires in a fixed position, thereby facilitating the interconnection ofinsulated wires. It is significant that two pairs of upwardly extendingcontact fingers (141, 142) are provided because it is generallynecessary to handle incoming and outgoing wires in typical telephonewiring. Bridging connections onto a single wire pair is preferred over a"star" wired configuration.

The connectors 140 are made from 15 mil stamped metal stock. The slantedportions at the extremities of the contact fingers are coined to assistin cutting through a wire's insulation. The contact fingers (141, 142,144) share a common region 143 that provides structural stability andelectrical interconnection.

Dielectric block 120 further includes jack support members 122 forreceiving jack frame 130. Jack support 122 comprises two upward standingmembers having a receiving portion 123 for engaging shoulder 133. Jackframe 130 further includes a pair of tabs 134, one on each side thereof,for interlocking with a pair of tab-receiving channels 124.Specifications for modular plugs and jacks such as used in connectionwith the present invention can be found in Subpart F of the FCC Part68.500 Registration Rules. Opening 135 is adapted to receive aconventional modular plug.

Lead frame 150 is an interconnection pattern stamped from 15 mil metalstock that is selectively gold plated in the region of the jack wires153. It is a single rigid piece-part whose peripheral support membersare not shown. It is captured on the bottom side of dielectric block 120which includes grooves having the same pattern as the lead frame itself.Lead frame 150 comprises 8 flat elongated conductive element thatindividually interconnect one of jack wires 153 with one of connectors140. Each conductor includes a wide area 152 and a narrow area 151. Thenarrow area accommodates interconnection with the downwardly extendingcontact fingers 144 of each connector 140.

Wires enter the connecting block through side openings (not shown) andare pressed into wire slots contained in terminal strip 121. The wiresmay be pushed into the slot by wire insertion cap 110 where insulationis displaced and electrical connection is made with one pair of upwardlyextending contact fingers (141 or 142) of connector 140.

FIG. 2 provides a more detailed view of the cooperation between leadframe 150, dielectric block 120 and jack frame 130. Although not shown,lead frame 150 includes small holes in the wide areas of each of itsconductive elements 152. These holes fit over cylindrical pins moldedinto the grooves at the bottom of dielectric block 120. Once lead frame150 is in place, the pins are deformed to hold it in place. Jack wires153 are deformed upwardly into cut-out area 125 of the dielectric block.Jack frame 130 is thereafter snapped into place, engaging each of thejack wires 153 individually into its vertical comb-like teeth 136.Wedge-shaped locking tabs 134 hold jack frame 130 in place.

FLUSH MOUNT CONNECTING BLOCK

FIG. 3 discloses a flush mount connecting block in accordance with asecond embodiment of the invention. Similar in shape to a conventionalelectrical power receptacle, it is designed to mount onto a wall surfacewith minimum protrusion away from the wall. Dimensionally, frame 300 isthe same size as the electrical power receptacle; it uses the same wallbox for convenient mounting and accepts the same faceplate. Jack frame330, spring block 360, and dielectric block 320 are dielectric partsthat snap together to enclose lead frame 350 and insulation-displacementconnectors 340.

Lead frame 350 includes jack wires 353 that are bent upwardly afterengagement with spring block 360. Spring block 360 includes supportmember 361 having grooves therein for containing jack wires 353, aroundwhich the jack wires are bent downwardly. After such bending, jack frame330 is joined to spring block 360 and held in place by locking tab 334.Y-shaped connectors 340 electrically interconnect with the conductivepaths of lead frame 350 and slide into apertures 326 of dielectric block320. Wires pressed into terminal strip 321 have their insulationdisplaced by connectors 340 and enjoy good electrical and mechanicalconnection. Wire insertion cap 310 assists in this operation.

WALL MOUNT CONNECTING BLOCK

FIG. 4 discloses a third embodiment of the present invention designed tofunction both as a connecting block and as a mechanical support for wallmounted telephones. While similar to the embodiments of FIG. 1, FIG. 3it differs in that the connectors are now an integral part of the samelead frame, and in the two-piece construction of the terminal stripsupporting the insulation-displacement connectors.

Bracket 460 is a single-piece, molded, dielectric part that cooperateswith lead frame 450 and dielectric block 420 to provide an easilyassembled wall mount connecting block. Bracket 460 includes four pins463 that secure lead frame 450 and dielectric block 420 in a fixedpositional relationship to each other. Although not shown, grooves aremolded into bracket 460 that match the shape of the lead frame'sconductive elements and hold the lead frame in place. Faceplate 400joins with bracket 460 using mounting studs 401 capable of supporting awall-mounted telephone set. Pins 463 are deformed to hold dielectricblock 420 in place.

Although not shown, lead frame 450 includes an outer carrier member thatholds the individual conductive elements 452 in a fixed positionrelative to each other until after the lead frame is joined to bracket460. The carrier is then cut away. Lead frame 450 is stamped from thesame material used in the lead frames of FIG. 1 and FIG. 3.Insulation-displacement connectors 451 are included in lead frame 450 asan integral part thereof. As with the other connectors disclosed, theends are coined to facilitate the cutting of insulation that surroundsthe wires to be pressed into the connectors.

Jack wires 453 are pre-formed by stamping and cooperate with supportmember 464 and jack frame 430 to provide a modular jack. Tool 422 isformed in the molding of dielectric block 420 as a part thereof, but iseasily broken away therefrom. It is used to facilitate the insertion ofwires into the slots formed by the joinder of dielectric block 420 andbracket 460. After usage, the tool is stored on pins 462 which passthrough mating holes molded into tool 422. Comb-like slots 421 and 461combine to form wires slots that align with each pair of opposingfingers on insulation-displacement connectors 451.

Although three different embodiments of the invention have beendisclosed, it is clear that various modifications are possible withinthe spirit and scope of the invention.

We claim:
 1. In combination:a metallic lead frame having a plurality ofsubstantially flat elongated conductive elements, said conductiveelements terminating in closely spaced flat wires at one end thereof,each conductor terminating in a pair of opposing contact fingers adaptedto displace insulation from a wire inserted therein, at the other endthereof; a first dielectric block for receiving the metallic lead frameand having a grooved support member around which the closely spacedwires are located; and a second dielectric block adapted to engage saidfirst dielectric block and sandwich the metallic lead frametherebetween, the second dielectric block including a jack housing forreceiving said grooved support member and containing the closely spacedflat wires of the metallic lead frame.
 2. The combination of claim 1wherein the first and second dielectric blocks each include a pluralityof corresponding slots positioned to guide wires inserted therein intothe region between said pairs of opposing contact fingers on the leadframe.
 3. A connecting block comprising:a metallic lead frame thatincludes a plurality of substantially flat elongated conductiveelements, each conductive element terminating, at one end thereof, in atleast two pairs of opposing contact fingers said plurality of conductiveelements and contact fingers all residing in the same plane, saidconductive elements terminating in closely-spaced flat wires at theother end thereof; a first dielectric block supporting the metallic leadframe on one side thereof; and a second dielectric block supporting themetallic lead frame on the other side thereof, the first and seconddielectric blocks being generally flat and cooperating with each otherto hold the metallic lead frame thereinbetween; whereby a low-profileconnecting block, suitable for wall mounting, is provided.
 4. Theconnecting block of claim 3 wherein each said dielectric block includesa plurality of complementary slots, positioned along an edge thereof,that are aligned with each other when the blocks are joined togethersuch that when the lead frame is positioned between the dielectricblocks, the slots cooperate to guide wires, pressed therein, intoassociation with said contact fingers of the lead frame.
 5. Theconnecting block of claim 3 wherein the second dielectric block includesa jack housing that receives the closely-spaced flat wires of the leadframe, and the first dielectric block includes a grooved support memberthat supports the closely-spaced flat wires of the lead frame and urgesthe wires into an opening in the jack housing of the second dielectricblock when said first and second dielectric blocks are joined together.6. The connecting block of claim 3 wherein one of the dielectric blocksincludes two or more pins molded therein and the other of the connectingblocks includes two or more holes therein, such that the pins and holesmate when the dielectric blocks are joined together and hold each otherand the lead frame in fixed alignment thereafter.